Systems for Data Monitoring and Management of Pipelines Assembled with Mechanical Press Fit Pipe Joints

ABSTRACT

Processes and systems for preparing pipe for machine processing to form pin and box ends for assembly into pipelines using mechanical press-fit pipe joints that are fully measured and documented during both manufacturing and assembly. Installed pipelines include pipeline data monitoring systems coupled to a pipeline data management center for receiving, archiving, and analysis of the data records to aid in administration, operation and management, and troubleshooting of pipelines.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/062,944 filed Oct. 12, 2014 by the same inventors andentitled SYSTEM AND METHOD FOR MEASURING AND MONITORING PARAMETERS OFPRESS FIT MECHANICAL PIPE JOINTS AND PRODUCING STANDARDS FOR SAME.Further, this Application is a Continuation Application of U.S. patentapplication Ser. No. 14/880,618 filed Oct. 12, 2015 by the sameinventors and entitled APPARATUS AND METHOD FOR ASSEMBLING, MEASURING,AND MONITORING INTEGRITY OF MECHANICAL PIPE JOINTS, and is related toco-pending U.S. Patent Application by the same inventors and filedconcurrently herewith entitled PROCESSES FOR PREPARING, FORMING ANDASSEMBLING PIPE SECTIONS IN A PIPELINE USING MECHANICAL PRESS FIT PIPEJOINTS.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention generally relates to mechanical press it pipejoints, and more particularly to a computer-implemented system andmethod for measuring and monitoring parameters of press fit mechanicalpipe joints during both manufacturing and assembly of pipe segments, theconstruction of pipelines, monitoring environmental conditions andstresses experienced by the mechanical press-fit pipe joints, andutilizing the data produced thereby to formulate standards formechanically joined pipe segments.

Background of the Invention and Description of the Prior Art

Pipelines for conveying commodities and other substances typically fluidmaterials, including oil and liquid products refined therefrom, as wellas natural gas, compressed gas, and CO₂ to name some examples—over longdistances are subject to a variety of conditions and forces that can actto cause failures in the pipeline such as breaks, ruptures, or leaks.These failures may be expressed by tension or compression forces exertedon the joint, or by bending, twisting, or vibration of the pipeline,etc., generally due to excessive internal pressures or geological ormeteorological conditions present at the location of the pipeline. Apipeline is typically constructed of sections of pipe joined togetherend-to-end by various means. The utility, integrity, and longevity ofthe pipeline in the widely varying conditions noted above dependscritically on the quality of the joints. A variety of methods are usedto join the pipe sections together, including but not limited towelding, threaded joints, cemented joints, and mechanical joints.

While capable of providing secure, reliable, and durable joints, themore common methods of welding, threading, and cementing involverelatively time-consuming, labor-intensive operations during manufactureor preparation such as the welding operation itself, machining the pipeends to cut the threads, honing and cleaning the surfaces to be joinedwhen cements or epoxy materials are used to join the sections together.These operations may extend the time to install a pipeline, and increasethe costs of construction, thereby reducing the productivity of theenterprise. Mechanical press fit joints, on the other hand, offer thepotential for rapid construction at much lower costs, eliminating asubstantial portion of the labor-intensive work of the traditionalmethods of joining pipe sections together. In a mechanical joint the endof one section of pipe, slightly enlarged (called a “bell” or “box” end)is forced—i.e., press fit—over the adjoining end of the other section,which may be slightly tapered (called a “pin” end) to accommodate thepassage of the box end over the pin end. Typically the ends thuspre-shaped are aligned and hydraulically pressed together until aprescribed amount of overlap of the box end of a first pipe segment overthe pin end of the adjoining pipe segment is achieved. Mechanical jointsthus firmed are rapidly made, resulting in much less time to construct apipeline, usually involving fewer workers.

However, mechanical joints rely principally on the uniformity and areaof contact along the interface between the pipe ends pressed together,one over the other, to provide and maintain the leak-proof integrity ofthe joints. To an observer during assembly of mechanical pipe joints,the only parameter of interest appears to be the amount of overlap ofthe two pipe ends under the pressure employed to assemble the joint,which is not subject to measurement during assembly. However, thisparameter does not take into account variations in the tooling (e.g.,due to wear or failure to maintain dimensions within tolerance),deformation of the pin or box ends of the pipe sections as may be causedby dropping the pipe sections on end during loading or unloading,defects in the surface of the contact areas of the pipe sections to bejoined (e.g., scratches or corrosion), the ambient temperature at thesite of joint making, or the temperature of the pipe sections at thetime of joint making, for example. Moreover, typical assembly practicesinclude no significant preparation of the pipe ends such as cleaning,inspecting, etc. to ensure that the pipe joint will have adequatestrength and integrity over its useful life.

As a result, mechanical joints are found less often in pipelinesdesigned for conveying flammable or toxic materials, for example, wherefailures may be catastrophic, damaging the environment, causing injury,disease, or death, etc. Moreover, the conventional method of gauging thecorrect assembly of box-to-pin ends of pipe sections—marking the pin endof one section to be joined with paint, wax, or chalk a few inches fromthe end to indicate how far the box end of the other section to bejoined should overlap the pin end—leaves much to be desired in terms ofrepeatability and consistency because of the reliance on a single,hand-applied mark and the manual coordination of the operators thatinscribe the mark, and apply the pressure to join the sections. Whilethis method is quick, the margin of potential error is substantial, andlikely insufficient to guarantee the integrity of the joint under allconditions, particularly if the pipe sections are out of spec as totheir dimensions, have detects or anomalies due to corrosion,deformation (e.g., departure from roundness), scoring, etc. Moreimportantly, there is no measure of the integrity of the joint, notraceable record or data of the joint or its assembly, no direct andverifiable relationship between the proximity of the end of the boxsection to the mark on the pin section and the ability of the joint thusformed to withstand the conditions of use in the pipeline.

Some potential for errors can be reduced through testing of samplejoints in a laboratory, using tests for pressure, tension, compression,bending, and perhaps twisting, temperature cycling, or vibration forexample. Assembly workers can measure the distance of the internalshoulder in the box or bell end from the end of the pipe (if one hasbeen machined therein) and use that dimension to place the mark in thepin end. However, even though such tests may be performed undercontrolled conditions, it is impractical to simulate all of thevariables that can occur in an actual installed pipeline, over the lifeof the pipeline. Because press fit mechanically joined pipe tends tolack the same degree of metal-to-metal contact that is consideredinherent in welded or threaded joints, ways to demonstrate the integrityand strength of press fit joints are needed so that mechanically joinedpipe can compete effectively with the traditional methods.

In the face of such simplicity and potential for error, and the lack ofperformance measures for mechanical pipe joints, what is needed areimproved methods for mechanically joining pipe sections together andimprovements in the methods for measuring the relevant parameters of amechanical joint to ensure that a joint of high quality, integrity, andconsistency is formed at each joint in a pipeline, and that enable theretrievable collection of data about the joints thus formed both as tothe original assembly of the joints and the performance of the joints insitu over time. Improvements must demonstrate superior performance atsubstantially reduced costs to become viable alternatives to thetraditional methods of welding, screw threads, or cementing the pipesections together.

SUMMARY OF THE INVENTION

Accordingly there is disclosed herein a process for preparing pipesections for operations to form the ends into pin and box configurationsfor forming mechanical press-fit pipe joints in a pipeline, comprisingthe steps of inspecting raw pipe sections for acceptance intopre-preparation processing; beveling, to a predetermined angle, aninside edge of an end of a pipe section to be formed with a pin endconfiguration; bypassing the previous step if the end of the pipesection is to be formed with a box end configuration; cleaning the innerand outer surfaces of the ends of the pipe section; applying a corrosioninhibitor to the cleaned inner and outer surfaces of the pipe section;and transferring the pre-prepped pipe section to a storage location orto an end-forming location.

In another embodiment of the invention, a system is disclosed forforming first (box) and second (pin) ends of sections of pipe to form amechanical press-fit joint between the sections of pipe in a pipeline,comprising: an end-preparation bench comprising a stationary toolingsupport and an opposing movable pipe clamp mounted on the bench, thestationary tooling support configured with a die for forming a box endor a pin end of a section of pipe, and the movable clamp connected to ahydraulic ram for drawing the movable clamp toward the stationarytooling support; a pressure sensor for measuring hydraulic line pressureP for operating the hydraulic ram; a stroke length sensor for measuringthe length L of travel of the die within or over the pipe end beingformed; a data acquisition unit coupled to the pressure sensor and thestroke sensor for receiving and converting outputs of the pressure andstroke sensors to digital form; a processor including non-volatilememory and a display, the processor coupled to an output of the dataacquisition unit and configured for measuring, under control of aprogram stored in the memory, the hydraulic pressure and the length oftravel of the die occurring while forming the respective box or pin endsof a pipe section supported in the movable clamp; and the processorfurther configured for displaying the measured hydraulic pressure P andthe stroke length L in graphical form on the display while forming therespective box or pin end of the pipe section.

In another embodiment of the invention, a process is disclosed forpreparing pipe sections for assembly in a pipeline using mechanicalpress-fit pipe joints to join the pipe sections, comprising the steps ofperforming a pre-preparation process for each section of raw pipe;forming respective pin and box ends of each section of pipe for joiningusing the mechanical press-fit pipe joints; measuring and storing atleast two parameters associated with preparing the pin and box ends ofthe pipe sections using a process monitoring computer system, wherein adata record of the at least two parameters of the formation of each pinand box end is created and stored; marking each pin and box end of eachpipe section with a permanent encoded data panel recordingidentification and end preparation data for the associated pin or boxend; coating the formed pipe sections according to specificationsapplicable to the expected use of the pipe sections in a pipeline; andinstalling a pipeline data monitoring bus on each section of pipe.

In another embodiment a system is disclosed for forming a pipeline ofsections of pipe using mechanical press-fit joints between first andsecond ends of the pipe sections, comprising: an assembly benchcomprising first and second opposing pipe clamps mounted on the benchand connected by a hydraulic ram for drawing the first and secondopposing pipe clamps toward one another; a pressure sensor for measuringhydraulic line pressure for operating the hydraulic ram; a stroke sensorfor measuring penetration of the first pipe end by the second pipe end;a data acquisition unit coupled to the pressure sensor and the strokesensor for receiving and converting outputs of the pressure and strokesensors to digital form; a processor including non-volatile memory and adisplay, the processor coupled to an output of the data acquisition unitand configured for measuring, under control of a program stored in thememory, the hydraulic pressure and amount of penetration occurring whileforming a press-fit joint of the pipeline; and the processor furtherconfigured for displaying the measured hydraulic pressure P and thepenetration L in graphical form on the display while forming thepress-fit joint of a pipeline; transporting the completed pipe sectionsto a pipeline site for assembly; assembling the pipe sections to form apipeline; installing pipeline sensor circuit modules and connect them tothe pipeline data monitoring bus; and testing the completed pipelinesystem for integrity and operation.

In another embodiment a system is disclosed for monitoring operationaland environmental conditions affecting an installed pipeline, comprisinga data monitoring bus installed on the pipeline surface; a data sensingmodule installed at each pipe joint and connected to the data monitoringbus; a pipeline data acquisition system communicatively coupled with thedata monitoring bus at selected intervals along the data monitoring bus;and a communication interface in the pipeline data acquisition systemcoupled via a network to a data management center for receiving,storing, and processing data provided and communicated by the datasensing modules.

In another embodiment a process is disclosed for measurement and controlof machine and assembly operations on sections of pipe to be used incommodity pipelines, comprising the steps of forming in respectiveopposite ends of the pipe sections a pin end and a box end, wherein atleast first and second predetermined parameters associated with formingthe respective ends are met within a predetermined tolerance duringformation of the respective ends; forming a mechanical press-fit jointbetween first and second sections of pipe in a pipeline wherein a pinend of the first section of pipe is inserted into the box end of thesecond section of pipe until the at least first and second predeterminedparameters are met within a predetermined tolerance during assembly ofthe mechanical press-fit joint; and measuring, and displaying on agraphic display, the at least first and second predetermined parametersas the pin end and box end are formed and as the first and secondsections of pipe are assembled together.

In another embodiment a data management system is disclosed forpipelines constructed using mechanical press-fit joints to connectsections of pipe together, comprising a data acquisition system coupledto the pipeline and to a network; a data management computer systemincluding at least one computer having a display, non-volatile memoryand a suite of applications software installed therein, the computersystem coupled to the network for processing data provided by the dataacquisition system; a database coupled to the data management computersystem for storing data originating from the data acquisition system andprocessed by the data management computer system; wherein the suite ofapplications software includes at least one operating program forprocessing data measurements regarding pipeline operating parameters andconditions originating from the data acquisition system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a system block diagram of one embodiment of thepresent invention;

FIG. 2 illustrates a portion of the system of FIG. 1 that is directed toprocessing pipe for use in the system of FIG. 1;

FIG. 3 illustrates a pictorial view of one embodiment of a pipe EndPreparation Machine for use in the embodiments of FIGS. 1 and 2;

FIG. 4 illustrates a pictorial view of one embodiment of a pipe AssemblyMachine for use in the embodiments of FIGS. 1 and 2;

FIG. 5A illustrates a first section of one embodiment of a flow chartdirected to the processes of preparing the Box end and Pin end of thepipe for assembly to construct a pipeline;

FIG. 5B illustrates a second section of one embodiment of a flow chartdirected to the processes of preparing the Box end and Pin end of thepipe for assembly to construct a pipeline;

FIG. 6A illustrates a first section of one embodiment of a flow chartdirected to operating the End Preparation and Assembly Machines of theembodiments of FIGS. 3 and 4 for the measurement of key parametersinvolved in forming the Box end and Pin end of the pipe sections and theassembly of the Box End and Pin end together to construct a pipeline;

FIG. 6B illustrates a second section of the embodiment of FIG. 6A;

FIG. 6C illustrates a third section of the embodiment of FIGS. 6A and6B;

FIG. 7 illustrates a screen shot of a graphical display that depictsdata measured during operation of the embodiments of FIGS. 3, 4, 5, and6;

FIG. 8 illustrates a method of interpreting the data displayed in thegraphical display of FIG. 7;

FIG. 9 illustrates one embodiment for monitoring the integrity of anassembled pipeline that utilizes pipe prepared according to theembodiments of FIGS. 1 through 8;

FIG. 10 illustrates one embodiment of a sensor circuit module for use inthe embodiment of FIG. 9;

FIG. 11 illustrates a cross section view of a die for forming the box orbell end of a section of metal pipe;

FIG. 12 illustrates a cross section view of a die for forming the pin orcone end of a section of metal pipe;

FIG. 13 illustrates a cross section view of an assembled mechanicalpress-fit pipe joint formed according to the present invention; and

FIG. 14 illustrates a detail cross section view of an alternateembodiment to the mechanical press-fit pipe joint depicted in FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION Introduction

In an advance in the state of the art a system and associated apparatusand methods are disclosed for forming mechanical press-fit pipe jointshaving more uniform and consistent performance, thereby overcoming thedeficiencies mentioned herein above. Data gathered, stored, and analyzedmay be utilized to control both the process for forming the pipe endsprior to assembling them and the mechanical press-fit joint assemblyprocess itself. The processes both produces superior mechanicalpress-fit joints and provides logging data for setting standards andenabling pipeline integrity monitoring to track pipeline conditions andperformance, detect malfunctions and failures, etc. Basic data such asthe pressure employed to form the pipe ends and assemble the mechanicalpress-fit joint, and the length of the overlap of the box (or bell) endinto the pin (or cone) end being formed or joined may be accumulated andused for pipeline logging, on-going analysis, and the development ofstandards for mechanical press-fit pipe joints and pipeline integrity ingeneral. Herein after the mechanical press-fit pipe joint may be calleda MPF joint, referring to pipe sections joined by the apparatus andprocesses described herein. A MPF joint is depicted in FIG. 13 asreference number 620.

The accumulated data may be developed into a standard index of thefitness of an assembled mechanical press-fit joint for use in monitoringassembly, formulating industry standards, etc. Superior joints may beensured when measurements made during preparation of the ends of thepipe sections and assembling the MPF pipe joints fall within a uniqueindex range derived from measured assembly data and subsequent test dataperformed on the assembled joints. Standards for pipe of different size,weight, wall thickness, material, and grade may be developed from theaccumulated assembly and test data. Monitoring of pipelines, either asroutine periodic inspections or to locate pipeline integrity deviations,may be facilitated by access to stored data and the ability of apipeline authority to utilize the tagging and logging systems disclosedherein to obtain accurate data regarding pipeline integrity. As is wellunderstood, monitoring and inspection regimens are critical to beingable to quickly locate and diagnose problems in pipelines, to discoversmall problems before they become large problems.

The system to be described may include a multiple input data acquisitiondevice coupled with a programmed processor and graphical user interface,wherein the graphical user interface may be controlled by specializedsoftware to enable the user to view the parameters of interest in realtime while a press-fit pipe joint is being assembled. These functionalunits may be embedded in a computer or provided as separate structures,collectively called a ‘computer.’ A database may be coupled to thecomputer or the system for accumulating data. Sensors connected to thedata acquisition inputs may include components that, for example, sensethe pressure P exerted to force the pipe sections together, the length Lof the stroke or overlap of the pipe ends being joined, and othersensors for indicating dimensions or temperature conditions. Thecomputer may be connected through the sensors to the hydraulic swaging(aka swedging) machines that perform the forming and assembly operationson the pipe ends. For example, the pressure measurement may be thehydraulic line pressure in lb./in² (“psi”) applied by the machine forassembling the formed ends to complete an MPF joint. The lengthmeasurement may be the distance in inches that the box end of a firstpipe section overlaps the pin end of the second pipe section beingconnected to the first section. The system may also be used during theprocess of forming the pipe box and pin ends on dies held by a mandrelin a suitable hydraulic swaging machine to be described. The pressureapplied directly to the mandrel/die assembly by the machine, and thetraverse of the die along the pipe end may also be measured and recordedby the apparatus and process to be described herein.

In measuring the overlap or stroke length L of the box end, one type ofsensor is called a string encoder (or string pot, draw wire, or yo-yopot). Other types of length sensors may include optical or acousticalmechanisms. Regardless of the method used to measure and indicate theoverlap length, a datum or starting point may be established, forexample by positioning the box end close to the pin end (within aprescribed tolerance, such as +¼-0 inch) and setting the overlap lengthmeasurement to zero. Various techniques for establishing such referenceare well known in the art. In measuring the pressure exerted by thehydraulic machine to form the pipe ends or to assemble the pipe endstogether, the pressure P is likewise set to a “low set starting point”such as 10 psi, which is a reference or initial condition value.

Other facilities provided in the system for the computer may include USBports for connecting keyboards, interfaces to GPS equipment, etc.;outputs for video or other baseband signals such as HDMI outputs; datalinks to databases to store the data with historical records;connections for links via Ethernet or other network interface standard,and the usual connections for power, indicators, etc. The computer maybe interfaced through suitable communication links with production orassembly apparatus, and may include control mechanisms for operating theproduction or assembly apparatus. Such mechanisms may include software,links to machine elements such as servomechanisms, switches, indicatorsand gauges, etc. Typical machine elements for forming the ends of thepipe include a hydraulic swaging machine. The forming die is supportedin a mandrel that is held by a stationary or moving portion of themachine. An assembly machine is very similar to a swaging machine exceptthat it forces two opposing pipe ends together under hydraulic pressurein the same manner as a swaging machine to join them together instead offorcing the end of one pipe section over a die to shape it.

Also to be disclosed herein is a new index developed to provide areadily observable and repeatable indication of the correct amount ofoverlap of the pin end by the box end to establish an acceptable MPFpipe joint. The purpose of such an index is to identify the instant thata correctly formed MPF joint is formed. One example is to multiply thehydraulic pressure P (lb./in²) used to press the two pipe ends togetherby the length of overlap L (in) of the box end over the pin end. Thisproduct has the units lb./in, which are the units of linear deflection,and may or may not be correlated with the amount of force needed toforce a box or bell end of pipe onto a pin or cone end of pipe. Thecombination of the values of P and L that indicate a correctly formedmechanical press-fit pipe joint is also clearly evident in a graphicalplot of P vs. L as shown in FIGS. 7 and 8 to be described.

The parameters P, representing the hydraulic pressure need to form theend of a piece of pipe or to assemble two formed pipe ends together, andL, representing the length of overlap of one section over the other orthe distance traveled in forming a box end to a pipe section, are basedon similar parameters of importance when assembling pipe sections byother methods, such as welding or screw threads. In both traditionalmethods of joining pipe sections, the length of overlap L is a keyparameter that is expressed by the dimensions of the box end that willoverlap the pin end of the opposing section. For welded joints thelength of overlap L will depend on the type of welding, the requiredstructure of the finished joint, and other factors such as the size andmaterial of the pipe. For threaded joints, characteristics such as thetype and pitch of the threads, whether sealants are used when assemblingthe joint, etc., along with the other characteristics of the pipe, willgovern the choice of the parameter L.

To understand why the parameters are useful in measuring the formationof mechanical press-fit pipe joints an example of a traditional methodof joining pipe ends together may be helpful. Steel pipe as used inpipelines is a heavy component, so turning a section of threaded pipeonto an opposing section of pipe having mating threads may require useof a hydraulic machine to provide the necessary motive power. As thefirst section advances onto (or into) the second section, a certainamount of friction within the threaded area must be overcome by thehydraulic pressure to operate the machine that turns the first sectionagainst the friction developed in contact with the second section. Asthe joint nears completion, the end threads of one of the sections arereached, causing the hydraulic pressure to increase more rapidly. Thiscondition indicates a joint that is close to being fully formed. Infact, the particular pressure can be a useful measure of a sufficientlythreaded joint. Before that pressure is reached, the joint is likelyincomplete; beyond the point where the pressure P begins to increasemore rapidly is a reference pressure that if exceeded may result instripped threads, a split pipe or other defects. The pressure indicatinga proper threaded joint would be expected to lie between these twovalues, and will likely be closely related to the length of overlap, L.Similarly, for welded joints, the dimensions of the pipe, in particularthe portions of the box and pin ends that are in contact—such as thetotal surface area in contact of the joint will be related to thepressure P needed to assemble the pipe ends together and the length ofoverlap L.

One way to visualize the effect of these two variables P and L is toplot one variable vs. the other on rectangular coordinates. This willyield a curve having a positive slope as the pressure increases withincreasing overlap. If the acceptable values of P and L are given atolerance, say 5%, for example, then an acceptance rectangle defined bythe minimum and maximum permitted values of both parameters can besuperimposed on the graph and its area can be calculated or delineatedon the graph. The tolerance in this example is chosen to illustrate theconcept. The correct tolerance may be developed from empirical dataobtained during actual use. Operation of the apparatus that joins thepipe ends together until the P-L curve enters the acceptance rectangleprovides a readily observable indicator of a correctly assembled joint.Further, the measured values input to the computer by the sensors appearon the graphic display and also may be stored for later use. The indexmay be called “the force-fit number,” “the PL product,” or “the pressfit product” for example. If the “PL product” is within this acceptancewindow on the graphical display, it is because the product of thepressure P and the length L correlates with substantial and uniformmetal-to-metal contact between the box and pin ends of the pipe. This isjust one example of an index and its use in facilitating the assembly ofpress fit mechanical joints in pipe.

The index described above may be related to other variables such as thetemperature at the construction site. The accumulation of data for manyinstallation sites, type and size of pipe, along with the values of P,L, and temperature T may suggest process variations that ensure the mostreliable press fit pipe joint. The accumulated data may be recorded intables to assist in set up of the press fit apparatus for assembling thepipe, either for constructing new pipelines or repairing old ones toreturn them to service. Such data can be important because temperatureaffects not only the malleability of the pipe material, its dimensionalvariations due to expansion and contraction, but also the viscosity ofthe hydraulic fluid used in the press fit apparatus. If sealingcompounds or epoxy or other adhesive materials are use in the joint,their properties will also likely be affected by temperature variations.In general, assembly tables for MPF joints may be constructed for anyvariable representing a parameter involved in the press fit assemblyprocess.

The data thus accumulated may be accessible to qualified users orsubscribers, to pipeline authorities, pipe manufacturers, pipelinecontractors, and the like. The data may be viewed as historical data orobserved in real time. Data may be correlated with a particularmanufacturer or mill that produced the pipe being installed. Access tothe data may readily be provided via the Internet or other networks.

Description of the Press-Fit Apparatus

The press fit apparatus to be utilized in the system and processdescribed herein includes two hydraulic press devices. They are similarin appearance, but are configured differently to fulfill their specificfunctions. Each may be thought of as a bench or frame equipped withrails along which hydraulically operated clamps or stocks are mounted.In an “end preparation” machine, a sliding stock may be mounted on therails at the end of the bench connected to a source of hydraulicpressure. The sliding stock supports tooling—a die held by a mandrel—forforming either of the pipe box or pin ends. On the opposite end of therails a clamp assembly for securely hold the pipe section to be formedmay be fixed to the rails along the same longitudinal axis as the die.The movable die may be forced or driven toward the stationary pipe endunder hydraulic pressure supplied to the movable stock by a hydraulicpump. The hydraulic pump may be driven by an internal combustion engine,typically a diesel engine. The end preparation machine may typically beused at a site convenient for forming the box and pin ends of the pipesections. The site may or may not be located at the site where the pipeline is being constructed.

The clamp section may have hydraulically operated hemispherical jawsjoined on one side at a pivot along a radius spaced just beyond thehemispherical portions so that the jaws may be placed around the pipe tobe gripped and drawn together by hydraulic pressure to clamp the pipe inposition. The open ends of the jaws may be coupled together along ahydraulic cylinder to enable the jaws to be opened and closed. Thehemispherical jaws maybe fitted with dies to fit the particular diameterof pipe to be joined.

In a “field assembly” machine, which is very similar to a hydraulicallyoperated swaging machine apparatus, the rails on the bench or framesupport two opposing clamp sections that may be used to support the pipeends to be joined. One of the clamps may be secured to the rails, whilethe other one may be configured to slide along the rails under theapplication of hydraulic pressure to cylinders secured to the slidingclamp. As in the end preparation machine, the rails ensure T least oneof the clamp sections can move toward and away from the other clampsection while maintaining a fixed longitudinal relationship with eachother, thus ensuring that the pipe ends to be joined are correctlyaligned. The same type of pivoting jaw clamp sections may be used tosecure the pipe ends for joining. In use at a pipeline site, theassembly machine may be supported by a side crane mounted on a transportvehicle. A hydraulic pump for operating the filed assembly machine maybe driven by an internal combustion engine such as a diesel engine. Thevehicle can thus travel along the side of the site to position theassembly machine at the location of each pair of pipe ends to be joined.

Both the end preparation and field assembly machines may preferably becoupled to a computer monitoring system (“CMS” or, “computer”) formeasuring certain selected parameters involved in the MPF jointoperations, including either the preparation of the pipe ends forjoining or the assembly of the prepared ends in the field. The CMS, partof a process monitoring subsystem 24 (See FIG. 1), may preferably beprogrammed for processing measurement data provided by appropriatesensors, for converting the data to a form that may be displayedgraphically on a display screen, for storing the data and processedforms of it (“data products”) in a database, and for communicating thedata and data products via a network to external locations for data andprocess management, and the like.

The system for operating the end preparation and field assembly machinesalso includes a data acquisition unit coupled to inputs of the CMS forreceiving the parameter sensor outputs and converting those signals todigital form for processing by the computer monitoring system. Thesensors may preferably be transducers for measuring the hydraulic linepressure P supplied to the hydraulic cylinders that operate the endpreparation and field assembly machines, and a linear displacementtransducer for measuring the length of the stroke L necessary to providethe correct amount of overlap of the box end of one section of pipe overthe pin end of the adjoined section of pipe. Examples of a linear gaugetransducer include a “string potentiometer” (or “string pot” or “yo-yopot”), and a laser displacement meter, which are well known in the art.The operating programs that controls the CMS may be stored innon-volatile memory in the computer monitoring system.

A graphical display screen coupled to the computer is preferably used todisplay graphs of the parameters or data products produced by the CMS.Of principle interest is a plot of the hydraulic pressure P used toadvance the movable clamp holding a pipe end toward its opposite numbereither the forming die or tooling of the end preparation machine or theclamp holding the end of the other section of pipe to be joined—and thelength L of the overlap stroke produced during the formation of amechanical press-fit joint. The pressure P is plotted versus the lengthL, P along the vertical axis and L along the horizontal axis. Theresulting curve typically has a positive slope as the pressure increaseswith the increase in length of overlap. The slope and shape of the curvemay contain information about the condition of the formed joint oroperating conditions of the machine being monitored. This information ishighly useful in gauging the quality of the joint and its longevityprospects, and is also useful in diagnosing anomalies in the pipe or thejoining process. Further, as the data is stored for later analysis andthe creation of a historical record, much can be learned about the pipematerials, the processes used in its manufacture and assembly, and aboutthe integrity of the pipeline and pipeline joints in future years. Thehistorical data in particular will be instrumental in developing bettermethods of joining pipe sections together in the field.

Detailed Description of the System

In the following description, reference numbers appearing in more thanfigure refer to the same structures. FIG. 1 illustrates a system blockdiagram of one embodiment of the present invention. This embodimentdepicts the major components or subsystems of the system 10 thatreceives raw pipe 60 in a manufacturing environment, processes the pipeto prepare it for assembly into a leak-proof pipeline formed usingmechanical press-fit pipe joints. The system 10 also provides forassembling the pipe to construct the pipeline while providing built-infacilities for measuring and accumulating data generated during themanufacturing, installation, and monitoring processes for analysis,maintenance, management, and the development of pipeline standards. Notshown in FIG. 1, as they are well known in the art, and do not form partof the present inventions, are the various transport and storagefacilities that might, depending on particular circumstances, beinvolved in conveying the pipe through the series of subsystems depictedin FIG. 1.

The system 10 includes a series of major functional subsystems,beginning with facilities 12 for the receiving standard sections of rawpipe 60 (typically each 40 feet long) for undergoing the processes ofpreparing the ends of the sections of pipe 60 to be assembled into apipeline using mechanical press-fit joints. The mechanical press-fitpipe joints referred to herein are forced together under pressure andrequire no welding or machining of screw threads of the ends of the pipeto join the sections together end-to-end at the pipeline installationsite. The next subsystem comprises facilities 14 for forming the ends ofthe pipe to be joined together as mechanical press-fit joints. Thefacilities 14 may include machine apparatus powered by hydraulic pumpscontrolled by an operator (the hydraulic machine control 22), whereinthe processes are monitored by a process monitoring computer 24 forreceiving sensor data and displaying parameters of some of thepreparation steps in graphical form on the display 26. The machineapparatus 14 supports the pipe end being formed in longitudinalalignment with a die as the die is forced over the pipe end underhydraulic pressure.

After the ends of the sections of pipe are formed into a box (or bell)end at one end and a pin (or cone) end at the opposite end in subsystem14, the pipe sections are ready for assembly into the pipeline at theconstruction site, as represented by subsystem 16. The assembly of thepipe sections includes a machine apparatus powered by hydraulic pumpscontrolled by an operator (the hydraulic machine control 22), whereinthe processes are monitored by a process monitoring computer 24 thatdisplays parameters of some of the assembly steps in a graphical form onthe display 26. The machine apparatus in subsystem 16, which may be aswaging machine adapted for handling pipe sections, supports thesections of pipe in longitudinal alignment as they are pressed togetherunder hydraulic pressure.

During the formation of the pipe ends and the assembly of the pipesections, apparatus that contains sensors and circuitry for monitoringthe integrity of the assembled pipeline may be installed on the sectionsof pipe. The integrity monitoring circuitry applied in subsystem 18continually measures a variety of conditions of the pipeline followingits construction to provide for maintenance and safe, efficientoperation of the pipeline. The data generated in subsystem 18 maypreferably be forwarded to a pipeline data acquisition station 20.

Other components of the system include a hydraulic machine control 22coupled to each of the formation 14 and assembly 16 machine apparatus.In typical embodiments these may be manually-operated controls andappropriate sensors 23 (as will be described) for measuring selectedcontrol parameters. A process monitoring computer 24 may be coupled tothe machine control subsystem 22, 23 for receiving the sensor data anddeveloping responses thereto. A display 26 connected to the processmonitoring computer 24 provides visual, graphical representation of thecontrol parameters. A process program for controlling operations of theprocess monitoring computer 24 including the graphical display of thehydraulic pressure P and the stroke length L may be stored in thenon-volatile program memory. The process monitoring computer 24 mayfurther include a communication interface for coupling to a network 36.The pipeline data acquisition subsystem 20 also preferably includes acommunications interface coupled to the network 36. The network 36enables data communication of the subsystems 20 and 24 with a datamanagement center computer 40 (aka “DMC 40”) for archiving andprocessing the data regarding the preparation, assembly, and monitoringof the pipe sections and the completed pipeline. A database 42 anddisplay 44 are provided to facilitate the archiving and processingfunctions of the subsystem 40.

The DMC 40 computer may be a system of computers, servers, etc. asneeded to perform the functions assigned to it in gathering, analyzing,and otherwise processing the data sent to the DMC 40. These and otherfunctions may be provided by appropriate software developed for thepurposes of managing these functions. A suite of applications software38 may include at least one operating program for processing datameasurements regarding pipeline operating parameters and conditionsoriginating from the data acquisition system such as the hydraulicpressure P and the stroke length L data acquired during theend-preparation and field assembly operations. The data managementcenter computer 40 may further be utilized in a data management systemresponsive to data obtained during monitoring of pipeline data byapparatus coupled to installed pipelines. Data communicated to the datamanagement center computer 40 may be processed by components of thesuite of applications software 38 accessible from the data managementcenter computer 40. The suite of applications software 38 includes thenecessary storage facilities, which may be directly coupled to the datamanagement center computer 40 or accessible via a network to remotestorage facilities, as is well understood in the art. The data obtainedby such apparatus (to be described with FIGS. 9 and 10) may be processedand forwarded to the data management center computer 40 to performservices as described above under the control of the suite ofapplications software 38 selected or developed for these purposes aswell as administration, troubleshooting and overall managementactivities for pipeline operators and other entities responsible for thesafe and efficient operation of the pipeline.

FIG. 2 illustrates a pipe process system 50 that is directed toprocessing pipe for use in the system of FIG. 1. This figure expandssomewhat the components of subsystems 22 and 24. The process monitoringcomputer 24 includes a number of functional sections: a CPU, program anddata memories (including a non-volatile memory), and data acquisition,I/O, display processing, a GPS (global positioning satellite) receiver,and communication interfaces (including Ethernet). A keyboard 27 andmouse 29, and a GPS antenna may be connected to respective I/O and GPSreceiver ports of the computer 24. The Ethernet port may be coupled witha satellite link or other communications provider. The data acquisitioninputs may preferably be connected to the outputs of sensors, coupled tothe hydraulic machine 22, providing signals for hydraulic pressure, alength gauge, ambient temperature, and hydraulic fluid temperature.

The hydraulic machine 22 is typically powered by a hydraulic power unit30 such as a diesel powered pump (not shown) equipped with a manifold,fluid lines and valves to control the flow of fluid under pressure toactuators on the machines. The hydraulic machines may be operated by anoperator using a manual control unit 32 while observing the display 26that graphically displays the operating parameters while forming orassembling a mechanical pipe joint. One feature incorporated into thesystem of FIG. 2 is a dump valve 34 that may be operated manually orautomatically to divert the high pressure flow of hydraulic fluid to areservoir (not shown) associated with the hydraulic pump system inresponse to an abnormal operating hydraulic pressure as observed on thegraphical display. This action stops the operation of the hydraulicmachine apparatus to permit the operator to attend to the circumstancesof the work piece—the pipe—that triggered the dump valve operation. Thedump valve 34 is coupled in the hydraulic feed lines to the hydraulicmachine. For example, if the pressure is excessive, the dump valve 34may operate automatically; conversely, if the hydraulic pressure isinsufficient, the operator may manually trigger the dump valve 34. Otherconditions may be established for the operation of the dump valve 34.

FIG. 3 illustrates a top side pictorial view of one embodiment of a pipeEnd Preparation Machine 70 for use in the embodiment of FIGS. 1 and 2.The end prep machine 70, supported by base 72, is configured to form thebox and pin ends of a section of pipe so that the sections of pipe canbe assembled, end-to-end, to form a pipeline, as depicted in FIG. 13 tobe described. A sliding stock 80 (including a mandrel), which travels onguide rails 84, is driven by hydraulic cylinders 74 that cause the driverods 76 to advance the sliding stock 80 along the guide rails 84. Thesliding stock 80 is enabled to slide along the guide rails 84 for adistance that exceeds by a suitable margin the required length of thestroke to fully form the box end 504 or pin end 506 (see FIG. 13) of thepipe section during the end prep operation. The sliding stock 80supports a die 82 (see FIG. 11) in the mandrel. The die may be either abox end die 600 or a pin end die 610 as shown in FIGS. 11 and 12. Thesliding stock 80 advances the die 82 toward the facing pipe end 60supported in a pipe clamp 90 that is secured to the base 72 of the endprep machine 70. The pipe end 60 is clamped in the jaws of the pipeclamp 90. The jaws of the pipe clamp are caused to move closed or openby the hydraulic cylinder 92.

Continuing with FIG. 3, measurement of the displacement or stroke lengthof the sliding stock to form the pipe end may be using any of severaldevices including a displacement measuring device selected from thegroup consisting of a string potentiometer, a measuring tape, and alaser rangefinder. In the illustrated example, string pot 110 may besecured to the pipe clamp 90 for measuring the length of the stroke Lneeded by the die 82 to fully form the pipe end 60. A string gauge 114,which is a length of line retractably stored in the string pot 110, maybe secured in this example at its distal end to a tie point 116 attachedto the sliding stock 80. As the sliding stock 80 moves from apredetermined reference (“zero”) position the sting pot 110 measures theamount of string gauge 114 that is retracted as the die 82 advances fromthe zero reference L=L₀ to overlap the pipe end 60 by a specified amountL=L_(f) to form a fully completed mechanical press-fit joint at L=L_(f).This amount of retracted string gauge, sensed by the string pot 110 andconverted to units of length—e.g., inches (“in”)—is equal to the lengthL that is displayed in the graphical display and viewed by the operatoras the pipe end is formed. The length measurement sensed by the stringpot 110 is coupled to the data acquisition input of the processmonitoring computer 24 via line 118. In other embodiments, the stringpot 110 could be mounted to measure the value of L as the string gaugeis fed outward.

Hydraulic pressure for operation of the end prep machine may be suppliedfrom a diesel powered hydraulic power unit 30 through line 39, under thecontrol of the manual control 32. Line 39 may be multiple linesdepending on the structure of the hydraulic cylinder(s) used to powerthe sliding stock 80. Line 39 connects to the output of a junction block100 that is supplied hydraulic fluid under high pressure from thehydraulic power unit 30 through a valve 102 controlled by the control32. The amount of pressure—e.g., lb./in² (“Psi”) is sensed by transducer104, which is coupled to an input to the data acquisition section of theprocess monitoring computer 24 via a line 108. This transducer providesthe sensor signal corresponding to the hydraulic pressure P to bedescribed herein below. The junction block 100 includes the dump valve34 that is controlled via a line 106 from the process monitoringcomputer 24 when it is necessary to interrupt the flow of hydraulicfluid to the hydraulic cylinders that control the advance of the slidingstock, for example when the pressure P exceeds a safe value. The dumpvalve 34 may also be manually operated by an operator (mechanism notshown for clarity, but is well known in the art).

FIG. 4 illustrates a top side pictorial view of one embodiment of a pipeAssembly Machine for use in the embodiments of FIGS. 1 and 2. Theassembly machine 70, supported by base 132, is configured to form amechanical press-fit pipe joint between first and second sections ofpipe to form a pipeline, as depicted in FIG. 13 to be described. In thisexample, the box end 122 of the first section of pipe 120 is clamped inthe jaws of a pipe clamp 150 that is secured to the base 132. The pinend 124 of the second section of pipe 126 is clamped in the jaws of asliding pipe clamp 160. The secured pipe clamp 150 is operated by ahydraulic cylinder 134. The sliding pipe clamp 160 is operated by ahydraulic cylinder 136. The sliding pipe clamp 160 travels along thepair of rails 138 as they are drawn toward the secured pipe clamp 150 bythe hydraulic cylinders 140. The hydraulic cylinders 140 are powered bythe hydraulic lines 41 that are connected to the junction block 100.Similarly, the hydraulic cylinders 134, 136 for operating the pipeclamps 150, 160 are supplied hydraulic fluid from the hydraulic powerunit 30 via lines 43.

The remaining structures of FIG. 4 are identical structurally andfunctionally with the respective components of FIG. 3.

Description of the Mechanical Press-Fit Processes

FIGS. 5A and 5B illustrate one embodiment of a flow chart directed tothe processes of preparing the Box end and Pin end of the pipe forassembly to construct a pipeline. The initial steps, called “pre-prep”include cleaning and machine operations designed to condition the pipesurfaces and provide a uniform finish on the surfaces of the pipe endsto ensure a secure and liquid tight mechanical joint free of voids and“holidays” (gaps), scratches and uneven surfaces that would impair theintimate metal-to-metal contact between the joined surfaces. Thesepre-prep steps may include the application of certain lubricants andcorrosion inhibitors to be described to facilitate the pre-prep processin forming a consistent, uniform, finished surface to minimize“holidays” (gaps, scratches, voids, etc. in the surface of the pipe),prevent corrosion, and protect the surfaces from damage. The objectiveis two-fold: (a) to ensure a secure and leak-proof joint; and (b) toensure the repeatability of measurements made during and afterpreparation and assembly of the mechanical press-fit pipe joints.

The pre-prep steps of FIG. 5A may also include sand blasting or honing(or alternately, wire brushing) to remove corrosion (and provide a baremetal or “white metal” finish) and the use of certain tools such ascutting or grinding tools for cutting or grinding portions of the pipeend to a specified profile, and for finishing or smoothing the surfacesin preparation for an application of certain substances to clean orprepare a joint surface for making the joint. As is well understood inthe art, the operations of honing and wire brushing may include the useof honing or cutting oils to facilitate the operation, extend the lifeof the honing tool (if used), and flush the debris removed by theoperation away from the cleaned surface. The surface finish required isin the range of “roughness average” R_(a)=1 to 3 mil (i.e., 0.001 to0.003 inch). R_(a) is defined as the average of the peak roughnessvariations above the mean value. A similar parameter of measurement maybe expressed as the RMS or root-mean-square value of the peak deviationsin the surface profile.

Following the cleaning operations, the application of corrosioninhibitors may be preferred. Corrosion inhibitors of two types may beused; one is solvent based, the other is mineral oil based. Each may beselected to suit a particular set of conditions of the pipe segment andsubsequent process steps, environmental conditions, etc. For example,while the solvent-based corrosion inhibitors do not require an extrastep to remove them prior to coating or other operations, the oil basedcorrosion inhibitors generally require a light spray coating of acleaning fluid just prior to the end-forming processes in the swedgingmachine operations as described below using the machines depicted inFIGS. 3 and 4. Corrosion inhibitors may also have “dewatering”properties, i.e, the ability to shed water as a means of retarding newcorrosive processes of the “white metal” surfaces.

Proceeding with FIG. 5A, the flow begins at step 200 and advances tostep 202 to begin pre-preparation processing of the pipe ends forpreparation to be joined. Step 202 may include delivery and sorting ofthe raw pipe to an inspection site. Next, step 204 includes visualinspection of the ends to be prepared, followed by step 206 forselecting the pin end of the section of pipe for a machine bevelingoperation in step 208. The machine beveling operation will produce anoutward bevel profile 626 (“bevel 626”) at the edge of the pin end ofthe pipe. The bevel amount is typically set to approximately 8 degreesrelative to the longitudinal axis of the pipe and may extend forapproximately 1.00 inch along the inner surface of the pin end of thepipe. These figures are typical for nominal, medium pipe sizes (e.g.,with O.D. in the 6 to 8 inch range). For pipe of smaller or larger O.D.it may be necessary to adjust the values of this bevel profile. Thebevel 626 provides a taper that slightly expands the inside diameter ofthe pin end of the pipe at the edge of the pipe end so that when a pinend is mated within a box end, the internal edge of the formed MPF jointpresents minimal obstruction to the flow of fluids within the assembledpipeline. The bevel or taper 626 applied to the inside surface of thepin end, extending for a short distance along the inner surface of thepin end also forms one-half of a “double taper” configuration of themechanical pipe joint. This configuration, with a first taper of theouter diameter of the pin end and a second taper along a short portionof the inner end approximates a seamless joint that is smooth bothinside and outside the pipe. See FIGS. 12 and 13.

Considering further the flow chart of FIG. 5A, both the box and pin endsare then passed to the cleaning step 210, which may include honing andbristle brushing the surfaces of the ends using lubricants such as ahoning oil doped with a high load bearing lubricant (“HLBL”), primarilyto extend the life of the honing tools. The cleaning process may befollowed by application of a solvent or mineral oil—based corrosioninhibitor, and protective coatings or sealants well-known in theindustry. In the following step 212, the fully prepped pipe sections maybe loaded into an end prep 70 machine (See FIG. 3) to form a box end orpin end. The process of forming the box and pin ends of step 212 isfurther described below in the description of FIGS. 6A through 6Cbeginning with step 306. When the pipe section is secured into the pipeclamp 90, and the box end die 600 or pin end die 610 (See FIGS. 11 and12 respectively) is secured in the sliding stock of the end prep machine70, the reference point or datum 83 for initiating the forming of thebox 504 or pin 506 end may be established in step 214. After the datum83 is set (as described in the following paragraph), the hydraulicpressure may be applied to activate the end prep machine 70, andmeasurements of the hydraulic pressure P and the length L of the strokerequired to fully form the box end 600 or pin end 610 may be made. Thesemeasurements, which are critical to verifying that a proper pipe end isformed, are recorded, and plotted on a graph 400 (See FIG. 7) forviewing by the operator of the end prep machine 70.

Setting the datum for P and L may be accomplished as follows. Once thepipe section 60 is secured within the pipe clamp 90 the free end of thegauge string 114 is extended from the string pot 3110 (mounted on thefixed pipe clamp in this example) and attached to the post 116 mountedon the sliding stock 80 that holds the box 600 or pin 610 die in themandrel 82. The sliding stock 80 is advanced along the rails 84 untilthe die 600 or 610 is within a predetermined distance of the pipe end.This distance, which may vary from zero to ¼ inch, for example, enablesthe string pot to be set to read zero inches at L=L₀. From this datumpoint, the length L being known as the objective will be reached whenL=L_(f) as shown in FIG. 3. This value of L_(f) may be entered into thedata record accumulated in a database as depicted in FIGS. 1 and 2.

It will be recalled that the traditional method of indicating thedistance the box end should overlap the pin end was to inscribe—usuallyby hand—a mark on the pin end using chalk or other readily visiblemarker. Then, when the box end is forced over the pin end, the force isapplied until the end of the box end reaches the mark on the pin end.Clearly this operation depends on skilled eye-hand coordination of theoperator of the machine applying the force to the box end, as well asother operating conditions of the equipment, etc. It is inherently anunreliable method of joining pipe ends together, partly because ofuncertain repeatability. Further, in the traditional method, no recordof the distance—the amount of overlap of the box end over the adjoiningpin end—was created, nor was the value of the length standardized or anyprocess used to verify its accuracy or ensure its repeatability for theparticular pipe segment undergoing the process. This lack ofverification or repeatability information impairs the ability todetermine the causes of mechanical pipe joint failures because there isno data to retrace the history of particular pipe joints. Withoutsufficient data about how pipe joints are prepared and assembled thereis no reliable way to make the claim that a pipeline has been properlyassembled and will withstand the operational, environmental, andgeological conditions that it will experience during the life of thepipeline.

In the present invention, the distance from the end of the pin end to“the mark” is defined as the value of L_(f) described in the foregoing.Thus, in operation, at the datum L=L₀ the hydraulic pressure maypreferably set to its initial value, for example, P=P₀=10 psi as anexample. The values of P and L having been set to their initial values,the hydraulic pressure may be increased gradually to cause the die 600,610 installed in the mandrel 82 to advance toward the end of the pipe tobe formed. Since the OD of the pin end is intentionally slightly largerthan the ID of the box end, an interference contact is established andconsiderable frictional resistance is encountered. This resistanceopposes the increase in hydraulic pressure such that the rise inpressure P is plotted in curve 400 (See FIG. 7) versus the length ofstroke L that is required to fully form the pipe joint. The fully formedpipe joint will generally have P_(f) and L_(f) values within theacceptance range 460 shown in FIG. 8 to be described.

Returning to FIG. 5A, following step 214, the flow advances to step 216wherein the operator stops the machine when the correct values of P andL fall within the acceptance window formed by the maximum and minimumvalues of the parameters P and Las shown on the graph of FIG. 8. Thesevalues define the acceptance range or window 460 as will be describedindicating a fully formed and in-spec mechanical press-fit pipe joint620 as shown in FIG. 13. The pipe section may then be removed from themachine and inspected in step 218. If the pipe end does not passinspection, the flow proceeds to a step 220 to consider whether to scrapthe section of pipe or return it to step 200 for re-processing. If thesection of pipe passes the inspection, then the flow may proceed throughstep 222 that provides for marking the pipe section with a permanentlabel so that the individual section of pipe may be tracked duringmonitoring and the data accumulated may be retrieved and stored in adatabase for later analysis.

The marking step 222 may be accomplished by a variety of methods. Thepreferred method for the illustrated example is to etch, inscribe, orstamp into the metal surface a numeric code or serial number, includingcertain specific data, as expressed in alpha-numeric form or encoded asa bar code, which may preferably be a two-dimensional bar code. Oneexemplary type of two-dimensional data matrix bar code, applied by a dotpeening process, is available from Mecco Partners, LLC, CranberryTownship, Pa. 16066, Such codes can be read by industrial bar codereaders such as are available from Cognex Corporation, Natick, Mass.01760. The encoded data may include the location of the manufacturingplant, the date and time the pipe end was formed, the type end (box orpin), Mil specification data, etc. This data may be combined with the Pand L data obtained during the end preparation forming process in a datarecord established for each section of pipe. The data record may furtherbe supplemented by assembly data at the pipeline site, where theparameters P and L are again measured and stored in the data record aswill be described herein.

Decision step 224, following step 222 is provided to determine whetherthe pipe section 60 must be coated or undergo the installation of amonitoring bus conduit or whether it is to be transferred to storage orprepared for transport in step 226. If the pipe section is to be coated,such as for corrosion protection, another decision point is entered atstep 240 on FIG. 5B to decide whether a monitoring bus is to beinstalled on the pipe section as part of the process of the applicationof a coating. The monitoring bus may be a cable (aka, conduit),preferably equipped with connectors at each end, to be attached to theouter surface of the pipe section for connecting sensor elements andother circuitry for monitoring the condition of the pipeline as will bedescribed with FIGS. 9 and 10.

Before continuing with the process depicted in FIGS. 5A and 5B ofpreparing the pipe ends for assembly, there are three alternativeprocess steps that may involve coating the pipe sections before they arejoined together. The coating steps to be described may occur at severaltimes during the following processes. The steps may include internal orexternal coatings or both internal and external coatings of applying acoating, primarily as a corrosion inhibitor. In general, the process mayinclude applying a coating of solvent-based or mineral oil basedcorrosion inhibitor. Alternatively, the process may include spraying aprimer coating on the surface of the pipe followed by spraying a coatingof liquid epoxy onto the primed surface.

In pipe lines that will not have a monitoring bus installed on theexternal surface of the pipe, only the internal surface of the pipe willnormally be coated. If a monitoring bus is to be installed, the pipesegments will receive an external coating as part of the process ofinstalling the monitoring bus. In other instances, both internal andexternal coating is required. Thus, FIG. 5B outlines the process stepsfor coating the pipe segments, including the installation of themonitoring bus if required. Following the decision step 224 in FIG. 5A,the flow advances to step 240 to decide whether a monitoring bus is tobe installed. If YES, the flow proceeds to step 242 to determine whetherthe pipe section is to receive only an external coating. If NO, theprocess advances to step 244 to go through the internal coating processaccording to the applicable specifications. After coating the coatedpipe section (or segment) is inspected, and if it passes the flowproceeds to step 248 to install the monitoring bus on the pipe sectionby attaching it to the external surface of the pipe section. If thecoated pipe section did not pass inspection it is transferred to a scrapor rework operation in process step 268 for disposition.

In step 248, the monitoring bus may be attached to the external surfaceof the pipe section by means well known in the art, and disposed suchthat the connectors at each end of a monitoring bus segment areaccessible to be joined together across the press-fit pipe joint afterassembly of the pipe sections end-to-end to form the pipeline. Followinginstallation of the monitoring bus, the section of pipe passes throughthe external coating process to the applicable specification in step250. If the external coating passes inspection in step 252, the pipesection, complete with the monitoring bus and the external coating, istransferred to step 254 for transport or storage to await the assemblyof the pipe section into a pipeline.

Returning to step 240 of FIG. 5B, if it is not required to install amonitoring bus on the subject section of pipe, the flow enters a processto apply an internal coating to the pipe section, again according to theapplicable specification. This stage may be the same coating line as instep 244 or it may be a separate coating line, perhaps even at adifferent plant facility. If the coated pipe passes inspection in step262, the pipe advances to a decision step 264 to determine whether thepipe section, already coated internally is also to receive an externalcoating. If YES, the flow proceeds to the step 250 to be coatedexternally to the applicable specification. Again, this coating processmay be performed at a separate coating facility, depending on theparticular process sequence adapted by the processor. Subsequently, thepipe may undergo the same process steps 252, 254, 256 and 270, or 252,268 as described previously. Returning to step 264, if the decision isNO, the process follows the path to steps 254, 256, and 270 asdescribed. At step 270 the processes for preparing the ends of thesection of pipe, i.e., the box end and pin end of each section of pipe,are completed and the pipe is ready for assembly at the pipeline site.

The coating materials used in the processes illustrated in FIGS. 5A and5B include the application of corrosion inhibitors (see step 210) asdescribed, and applying a coating of an epoxy material—or,alternatively, a methyl methacrylate adhesive (“MMA”)—in steps 244, 250or 260 provided as a filler or sealant, and as an adhesive to ensure aleak-free mechanical press-fit pipe joint. The honing or wire brushingstep described previously (step 210) is needed to provide a surfaceroughness that is optimized for maximum adhesion of the epoxy or MMAmaterial. The internal coating may be an epoxy paint that is sprayed onor a fusion bonded epoxy (“FBE”) coating applied as a powder to theinterior surface of a pre-heated pipe section. The heat melts the powderto form a smooth, void-free coating. The coating operation may includemasking a portion of the pipe section. The external coating may also bean FBE coating applied to the exterior of the pipe section. The coatingsteps may include installation of a plastic protective cap over thefinished box or pin end when coating is completed. An additional coatingof the pin end of each pipe section is will described with FIG. 14.

FIGS. 6A, 6B, and 6C illustrate one embodiment of a flow chart directedto operating the End Preparation and Assembly Machines of theembodiments of FIGS. 3 and 4. The End Prep and Assembly machines arebasically variations of a swedging (aka swaging) machines operated underhydraulic pressure provided by a high capacity hydraulic pump, typicallydriven by a diesel engine. These operations include as essential stepsthe measurement of key parameters involved in forming the Box end andPin end of the pipe sections and the assembly of the Box End and Pin endtogether to construct a pipeline. The flow starts at step 300, followedby initializing the system at step 302 and a step 304 to determinewhether the process is set up for either (a) end preparation or (b)field assembly. It will be appreciated that the invention has beendevised to utilize very similar sequences of operations in both phases(a) and (b) of providing for reliable mechanically press-fit pipejoints. It should also be appreciated that both phases (a) and (b)include the measurement steps described herein for measuring andrecording the parameters P and L, a key step in the respectiveprocesses.

The dual sequences (a) and (b) are depicted in FIGS. 6A through 68. Ifthe process is to enter the “end preparation” path, the flow advances tostep 306 to install a first end of the pipe segment in the endpreparation bench and, in step 308, verify that the correct tooling isinstalled and the bench is reset to an initial condition. Similarly, ifthe process is to enter the “field assembly” path, the flow advances tostep 312 to install a first end of the pipe segment in the fieldassembly bench and, in step 314, verify that the correct tooling isinstalled and the bench is reset to an initial condition. It will berecalled from the description of FIGS. 3 and 4 herein above, that theend preparation and field assembly benches are quite similar inconfiguration and operation. In the case of the end preparationoperation, both ends of a section of pipe, typically 40 feet long, maybe prepared simultaneously using separate machines because the processsteps employ identical steps. Thus an end prep machine set up to prepareand form a pin end operates on that end of the pipe section while an endprep machine set up to prepare and form a box end operates on that endof the pipe section at the same time, each end prepared by a separatecrew to load, secure, and perform the required processes.

Following Step 316, the process follows the same steps whether formingthe pipe ends or assembling box-to-pin end to form a mechanicalpress-fit pipe joint. Thus, upon loading and securing the pipe sectionin the end prep bench in step 316, the flow advances to step 318 wherethe operator enters data about the pipe section in defined areas of thegraphical display (see FIG. 7). This data, which will be encoded in thepermanent tag or label 508 (See FIG. 9) may include but not be limitedto the date, the location (perhaps coded, or expressed in longitude andlatitude coordinates) of the facility, the operator ID, serial number ofthe pipe section, and pipe data such as its material and dimensions. Inthe next step 320, the operator sets the machine to an initial conditionby applying low pressure to advance the moving die to a reference,setting the P and L datum points, for example, to P=P₀=10 Psi andL=L₀=zero inches (0 in.) and recording these datum points on thegraphical display. Further in step 320 the operator sets the bench andthe alarm circuit to idle. The alarm circuit may be configured tooperate when the hydraulic pressure conditions fall outside acceptablevalues, which may result in triggering the dump valve 34 (See FIG. 2)and illuminate a warning light 444. The conditions for triggering thedump valve 34 are described below with FIG. 8. In step 322, the computermonitoring system (“CMS”), also known as the process monitoring computer24 herein, checks that the initial settings for P and L are withinspecification before engaging the machine.

In step 324, the operator engages the hydraulic rain, typically bymoving a lever or operating a switch on the control panel 32 (See FIGS.3 and 4) to form the respective pin or box end, or to assemble apress-fit pie joint. As the hydraulic pressure P and the stroke length Lincrease, the operator in step 326 observes the values plotted in realtime on the graphic screen (See FIG. 7) on the display 26 (See FIGS. 1and 2) and notes whether, in step 330 in FIG. 6B, all parameters arewithin specification. If a parameter is out of specification at anypoint, particularly as the end prep or the joint approaches completion,an alarm signal may be activated, which may be an indicator light(Reference No. 444 in FIG. 7) or an audible tone. This step will befurther described with the aid of FIG. 8. If an audible tone is used, awarble modulation or flashing light is preferred to indicate anout-of-specification parameter. This is especially important if theparameter P is excessive. Upon noting the alarm condition, the operatorin step 334 may shut down the machine, identify the anomaly, and takeappropriate corrective action. If the operation is not completedsatisfactorily the process in this example returns to step 304 per step338. If the operation is completed to specification, the flow advancesfrom step 338 to step 340.

Steps 340-344 are an interim or alternative sequence to cover asalternative embodiments the manual or automatic operation of the swagingmachines 70, 130 in response to the activation of an alarm condition. Ifmanual operation is preferred, the flow proceeds to step 342 to enablethe operator to control the shift of the machine to a neutral conditionto disengage the hydraulic ram of the swaging machine 70 or 130. Ifautomatic operation is preferred, the CMS 24 (aka the process monitoringcomputer 24) shifts the machine to neutral to disengage the hydraulicram and stop the machine.

When the hydraulic ram is disengaged and retracted in step 350, theprocess monitoring computer 24 logs the data of the parameters P_(f) andL_(f) along with the ID number, GPS coordinates, tag number, etc. beforeproceeding the step 352 to undergo the inspection of the completed pipeend or pipe joint. Upon verification in step 352 the flow advances tostep 354. If the process is forming a pipe end (box or pin) the pipesection may be released in step 356 and proceed to step 360. If theprocess is forming a pipe joint during field assembly, the fieldassembly machine (FIG. 4) is disengaged from the assembled mechanicalpress-fit joint in step 358 and moved to the next joint location.

Upon completion of the pipeline assembly, the pipeline is preferablytested in step 360 to confirm its functional utility and integrity. Thetesting may at a minimum comprise the steps of performing electrical anddata signal tests of the pipeline data monitoring system; performing apressure test of the installed pipeline for leaks and flow volume; andattaching ultrasound test apparatus to the pipeline for acoustic testingfor leaks and flow turbulence. While such tests are well-known in theindustry and not always carried out in practice, they are essential tothe operation of a pipeline constructed according to the principlesdescribed herein, to ensure an adequate data record for each joint ofthe pipeline.

If the respective process operations are to continue, per step 362, thedata log is updated and the pipe end tag—the permanent label discussedpreviously—is imprinted in step 364 before the process returns to step304 in FIG. 6A. If the process operation is to be discontinued, the datalog is updated and the pipe end tag is imprinted in step 366 followed byan option to print or save the updated log in step 368. If the data logis to be printed, the flow proceeds to step 370 followed by step 374,which is the end of the process depicted in FIGS. 6A through 6C. If thedata log is to be saved, the flow proceeds to step 372 to save to thedatabase 42 (See FIGS. 1 and 2) followed by step 374.

FIG. 7 illustrates a screen shot of a graphical display that depictsdata measured during operation of the embodiments of FIGS. 3, 4, 5A, 5B,6A, 6B, and 6C. The screen includes a graphed plot 400 of the changes inthe parameters P and L during the formation of a pipe end or theassembly of a mechanical press-fit pipe joint. Interpretation of theplot will be described in FIG. 8. The vertical axis 402 represents thehydraulic pressure P and the horizontal axis 404 represents the lengthL. The lines 406 and 408 represent respectively the maximum and minimumacceptable values of the hydraulic pressure P provided to the swagingmachines 70, 130 during operation of the respective end prep andassembly processes. A table of identification data 410 is shown in theupper left hand corner of the display. A linear graph 420 may beprovided as shown to display the numerical values 422 of the lengthparameter L, which is the displacement of the hydraulic ram during itsoperation. A pressure gauge 424 may be provided to display the numericalvalue of the hydraulic pressure P. Temperature gauges 428, 432 may beprovided to display readings of the ambient air temperature 430 and thehydraulic fluid temperature 434 as sensed by temperature sensors locatedproximate the swaging machines. The temperatures may also be graphed todisplay their variation in graphical form on graphs 440 and 442respectively as depicted in the upper right hand corner of the display.Also shown in FIG. 7 is an alarm indicator 444, which may include animage of a light next to the term “Alarm.” This feature may be includedto facilitate alerting an operator of a condition during operation ofthe machine as described in FIG. 6B at steps 330 to 334.

FIG. 8 presents a detail view of an exemplary graphical plot 400 of theparameters P and L, including acceptance ranges of the parameters, toassist in interpreting the displayed graphical plot 400. The maximum andminimum values of the hydraulic pressure P is represented by the dashedhorizontal lines 406 and 408 respectively. The maximum and minimumvalues of the length L is represented by the dashed vertical lines 450and 452 respectively. These values enclose a rectangular ‘window’ ofacceptance 460 for a finished process, whether it be a completed pipeend or an assembled pipe joint. The practical use of this ‘window’ 460is to let the operator know when a completed process is withinspecification. It is particularly useful during manual operation of themachine. It will be appreciated that the values shown are exemplary;actual values may be different than those shown for illustration and notintended to be limiting. Also shown in FIG. 8 are angled linesdelineating the preferred limits of the variation of P with L duringoperation of either end prep or assembly process. For example, thehydraulic pressure P should remain within the lines 454 and 456 for anormal process. If the plot 400 of hydraulic pressure P strays outsidethese limits at some point during the process, the indication is thatthe pipe end or joint being formed will contain a defect if the processis allowed to continue. These conditions may be associated with thealarm function to ensure that the operator is cognizant of the anomalousoperation. The lines 462 and 464 are shown to suggest when a connectionof a mechanical joint will be defective because either (462) thehydraulic pressure P is excessive at the associated value of the lengthL, or because the hydraulic pressure P is insufficient at the associatedvalue of the length L.

FIG. 9 illustrates one embodiment for monitoring the integrity of anassembled pipeline that utilizes pipe prepared according to theembodiments of FIGS. 1 through 8. A portion of an assembled pipeline 500is shown including components of a pipeline monitoring apparatusattached to the pipeline 500. Sections 502 of pipe are joined atmechanical press-fit pipe joints formed of pin ends 504 and box ends506. Each end of a section 502 of pipe is identified with a permanenttag 508 (such as the dot-peened tag previously described). Eachassembled mechanical pipe joint includes a sensor circuit module 510attached thereto. In the illustrated example, the sensor circuit module510 may be a thin film circuit that includes sensing elements 550through 556, interconnecting and processing circuits 512, 542, andtransmitting circuits 526, 528 as shown in FIG. 10 to be described.

Also depicted in FIG. 9 is a monitoring bus 514 that may be attached toeach respective portion of the pipeline 500 by means well known in theart, wherein the monitoring bus 514 is connected at each mechanical pipejoint by the connector 512 as shown. It will be appreciated that thepipeline shown is a representative functional example of the apparatusto illustrate one way the pipeline may be configured. The monitoring bus514 may further include such components as a power supply 520—forexample a rechargeable battery coupled to a solar powered rechargingsystem—an actuator 524 for controlling operation of the monitoring bussystem, a transmitter and antenna 526, 528 for communicating via anetwork 36 with a data management center 40 via the data receiver andantenna 530, 532. Data communicated to the data management centercomputer 40 may be processed by components of the suite of applicationssoftware 38 accessible from the data management center computer 40. Thesuite of applications software 38 includes the necessary storagefacilities, which may be directly coupled to the data management centercomputer 40 or accessible via a network to remote storage facilities, asis well understood in the art. Installing the pipeline sensor circuitmodules comprises securing a sensor circuit module 510 to the pipelineat each mechanical press-fit joint, connecting each module 510 to thepipeline monitoring bus 514, and connecting the power supply 520,actuator 524, and data transmitter 526 and its antenna 528 to thepipeline monitoring bus 514.

FIG. 10 illustrates one embodiment of a sensor circuit module for use inthe embodiment of FIG. 9. In this illustrative embodiment the module 510may be formed as a thin film circuit that includes sensing elements 550through 554, processing circuit 556, and transmitting circuits 526, 528as shown. In the illustrated example, a temperature sensor (for example,a thermocouple) 550, an acoustic sensor (such as a piezoelectricelement) 552, a strain gauge (which may also be a piezoelectricelement), and integrated circuitry that may include a processor, memory,data acquisition, and communication interface sections. These circuitelements and sensors may be coupled together and configured to outputdata to a transmitter and antenna for sending the data to a pipelinedata acquisition 20 location for connection via a network 36 to a datamanagement center 40 as shown in FIG. 1. A bus connector 512 may beprovided for connection to the pipeline monitoring bus 514. A connector542 may be provided for securing the thin film module 510 to eachmechanical press-fit pipe joint. The sensor module 510 is preferablysecured around the mid-point of the press-fit joint 620 (See FIG. 13)where the mating component of bus connector 512 is located.

FIG. 11 illustrates a cross section view of a die 600 for forming thebox or bell end of a section of metal pipe. The cross section isprovided to show that the internal diameter of the box or bell end to beformed by the die is to be slightly tapered at an angle of 4 degrees atthe forward or nose end of the die and at an intermediate angle of 2degrees between the forward or nose end and the nominal diameter of thetail end of the die, which corresponds to the outside diameter of thepipe to be formed.

FIG. 12 illustrates a cross section view of a die 601 for forming thepin or cone end of a section of metal pipe. The cross section isprovided to show that the external diameter of the pin or cone end to beformed by the die is to be slightly tapered at an angle of 5 degrees atthe forward or nose end of the die and at an intermediate angle of 2degrees between the forward or nose end and the nominal diameter of thetail end of the die, which corresponds to the outside diameter of thepipe to be formed. During assembly of a MPF joint a pin end formed bythe die of FIG. 12 is inserted under hydraulic pressure as describedpreviously into the box end of a pipe section formed by the die of FIG.11. As the pin end enters the box end, metal-to-metal contact will bemade and become more pronounced as the nose of the pin end approachesthe nominal inside diameter of the pipe. The outer surface of the pinend and the inner surface of the box end will be in 100% contact throughthe length of the joint and around the circumference of the pipesections in a completed MPF joint.

FIG. 13 illustrates a cross section view of an assembled mechanicalpress-fit pipe joint 620 formed according to the present invention, withthe pin end 504 fully inserted into and its outer surface in 100%contact with the inner surface of box end 506 throughout the full lengthof the MPF joint. Also shown in FIG. 13 is the effect of beveling theinside edge 622 of the pin end as described during the preparationprocess (See FIG. 5A, step 208 and its accompanying description). Thepurpose of this beveled edge 622 is to smooth the transition between thepin end and box end of the finished MPF joint.

FIG. 14 illustrates a detail cross section view of an alternateembodiment to the mechanical press-fit pipe joint depicted in FIG. 13.In this embodiment of MPF joint 628 an FBE epoxy material or a methylmethacrylate adhesive (“MMA”) coating 632 is shown. The coating 632 isapplied to the formed and prepared pin end just prior to assembly of theMPF joint of a pipeline. The epoxy material preferably forms a fillet634 at the nose of the pin end to smooth the transition of the pipelineinterior at the MPF joint. This coating also may function to ensureadditional adhesion and sealing of the joint. The space 630 mayrepresent an external coating of the pin end 504 or an internal coatingof the box end 506. The bevel feature of the pin end 622 is also shownin FIG. 14. The angle of the bevel feature may preferably beapproximately 8 degrees and extend along the inner surface of the pinend from the edge at its end approximately 1.00 inch. The angles give inthe foregoing exemplary description are intended to be illustrative andnot limiting because they will vary with the particular dimensions ofthe pipe and the specific circumstances of its use.

Conclusion

Disclosed herein are systems and methods concerning construction ofpipelines in at least four aspects including (1) the preparation ofsections of pipe to be joined by mechanical, press-fit joints; (2) theassembly of such sections of pipe; wherein the processes involved aremonitored by a computer programmed to measure and display to an operatorin real time parameters that indicate the quality of the pipe ends beingformed and the mechanical press-fit joints when being assembled. Thedata is accumulated and sent to a data management center for archivaland analysis purposes to provide source material for the development ofstandards for the construction, maintenance, and security of installedpipelines. (3) The sections of pipe formed and assembled by the systemand methods of the present invention include the components of apipeline integrity system that measures and monitors conditions of theinstalled pipeline such as stresses due to geological and climatologicalvariations, as well as internal pressures and temperature associatedwith the use of the pipeline to transport fluid commodities over longdistances. (4) This data accumulated is likewise sent to the datamanagement center to be stored and made available for analysis andmaintenance. The data management center can monitor all data receivedand determine when an emergency occurs that arise from leaks or stressesexperienced by the pipeline.

While the inventions have been shown in exemplary forms, they are notthus limited but are susceptible to various changes and modificationswithout departing from the spirit thereof. For example, the dataprocessing systems, apparatus, and methods described herein areadaptable to data monitoring and processing of other types of pipelinestructures. The data sensing and monitoring apparatus and methods arelikewise adaptable with little modification to other types of pipelinestructures. Various parameters of pipe characteristics may be monitoredusing the same concepts disclosed in the foregoing descriptions. Theprocesses for preparing the metal surfaces disclosed herein may bemodified as to technique and materials used without departing from theconcepts applied in preparing pipe materials for undergoing the formingoperations depicted and described herein. Further, the hydraulicmachines used in forming the mechanical press-fit pipe ends can be usedto form any pipe end and for other methods of joining pipe sectionstogether. Sections to be welded may have their ends “belled” to fit overan internal sleeve, as in a pipe joint to be welded, for example.

What is claimed is:
 1. A data management system for pipelinesconstructed using mechanical press-fit joints to connect sections ofpipe together, comprising: a data acquisition system coupled to thepipeline and to a network; a data management computer system includingat least one computer having a display, non-volatile memory and a suiteof applications software installed therein, the computer system coupledto the network for processing data provided by the data acquisitionsystem; a database coupled to the data management computer systemcontaining P and L parameter data, measured during the manufacture ofeach section of pipe in the pipeline wherein P=hydraulic pressure andL=displacement length, and stored data originating from the dataacquisition system and processed by the data management computer system;and the suite of applications software includes at least one operatingprogram for processing data measurements regarding pipeline operatingparameters and conditions originating from the data acquisition system.2. The data management system of claim 1, wherein the data acquisitionsystem comprises: a data monitoring bus installed on the pipelinesurface; a circuit module for sensing parameters installed at eachmechanical press fit pipe joint and connected to the data monitoringbus; a pipeline data acquisition processor communicatively coupled withthe data monitoring bus at selected intervals along the data monitoringbus; and a communication interface coupled between the data acquisitionsystem and a network coupled to a data management center for receiving,storing, and processing parameter data provided and communicated by thecircuit modules.
 3. The data management system of claim 2, wherein thecircuit modules comprise: sensors for sensing at least temperature,sounds associated with leaks in the pipeline or its joints, anddisplacement of pipeline structure caused by strain; a data acquisitionprocessor for receiving and converting sensor signals to digital format;and a transmitter for communication of the converted data via the datamonitoring bus to the pipeline data acquisition processor.
 4. The datamanagement system of claim 1, wherein the data management computersystem comprises: a processing center including an intracenter network;a plurality of work stations connected to the intracenter network; andat least one server system for interfacing the processing center with anexternal network.
 5. The data management system of claim 1, wherein thesuite of applications software further comprises: at least one operatingprogram for processing parameter data including measurements forP=hydraulic pressure and L=displacement length acquired duringoperations for forming pipe ends and for assembling pipe sectionstogether.
 6. The data management system of claim 1, wherein: thepipeline operating parameters and conditions are selected from the groupconsisting of at least temperature, sounds associated with leaks in thepipeline or its joints, and displacement of pipeline structure caused bystrain.
 7. A system for monitoring operational and environmentalconditions affecting an installed pipeline, comprising: a datamonitoring bus installed on the surface of a pipeline having its pipesections joined by mechanical press-fit pipe joints; a circuit module,installed at each mechanical press-lit pipe joint and connected to thedata monitoring bus, for sensing parameters of the operational andenvironmental conditions; a pipeline data acquisition systemcommunicatively coupled to the data monitoring bus at selected intervalsalong the data monitoring bus; a communication interface between thepipeline data acquisition system and a network coupled to a datamanagement center computer for receiving, storing, and processingparameter data provided and communicated by the circuit modules; and adatabase accessible by the data management center containing storedmanufacturing data for each section of pipe in the pipeline including atleast values of P=hydraulic pressure and L=displacement length acquiredduring operations for forming pipe ends and for assembling the pipesections together in the pipeline.
 8. The system of claim 7, wherein thedata monitoring bus comprises: a plurality of conductors for conveyingelectrical power and data signals; and a connector at the location ofeach pipe joint for connecting to a data sensing module.
 9. The systemof claim 7, wherein the circuit modules comprise: sensors for sensing atleast temperature, sounds associated with leaks in the pipeline or itsjoints, and displacement of pipeline structure caused by strain; a dataacquisition processor for receiving and converting sensor signals todigital format; and a transmitter for communication of the converteddata to a pipeline data receiver.
 10. The system of claim 7, wherein thepipeline data acquisition system comprises: a pipeline data transmittercoupled to the data monitoring bus; and a pipeline data receiver havingan interface for communicating with a data management center via aglobal network.
 11. The system of claim 7, further comprising: a datamanagement center computer for receiving, storing, and processing dataprovided and communicated by the data sensing modules; and a suite ofapplications software including at least one operating program forprocessing data measurements regarding pipeline operating parameters andconditions originating from the pipeline data acquisition system.